U.S. patent application number 16/015303 was filed with the patent office on 2019-05-02 for tunable compliant attachment structure.
The applicant listed for this patent is Unison Industries, LLC. Invention is credited to Dattu GV Jonnalagadda, Emily Marie Phelps, Joseph Richard Schmitt, Gordon Tajiri, Yanzhe Yang.
Application Number | 20190128143 16/015303 |
Document ID | / |
Family ID | 66242734 |
Filed Date | 2019-05-02 |
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United States Patent
Application |
20190128143 |
Kind Code |
A1 |
Tajiri; Gordon ; et
al. |
May 2, 2019 |
TUNABLE COMPLIANT ATTACHMENT STRUCTURE
Abstract
A tunable compliant mount structure for an engine such as a
turbine engine can include a fluid conduit coupled to a fan casing
by a connector. At a junction between the connector and the fluid
conduit, a compliant mount structure can provide compliance and can
be tuned to operate under variable stresses at the junction. The
compliant mount structure can include a set of nested convolutions
to provide compliance. The geometry of the convolutions can be used
to tune the compliance, stiffness, or directionality. The tunable
compliant attachment structure provides for additive in-situ
manufacturing at the fluid conduit.
Inventors: |
Tajiri; Gordon;
(Waynesville, OH) ; Phelps; Emily Marie;
(Bellbrook, OH) ; Jonnalagadda; Dattu GV; (Ponnur,
IN) ; Schmitt; Joseph Richard; (Springfield, OH)
; Yang; Yanzhe; (Mason, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Unison Industries, LLC |
Jacksonville |
FL |
US |
|
|
Family ID: |
66242734 |
Appl. No.: |
16/015303 |
Filed: |
June 22, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62577400 |
Oct 26, 2017 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F05D 2300/501 20130101;
F05D 2230/31 20130101; F05D 2260/94 20130101; F05D 2220/32
20130101; Y02T 50/60 20130101; F05D 2250/61 20130101; F01D 9/06
20130101; F01D 25/28 20130101 |
International
Class: |
F01D 25/28 20060101
F01D025/28; F01D 9/06 20060101 F01D009/06 |
Claims
1. A compliant mount assembly comprising: a conduit having an outer
wall defining an interior and extending between opposing ends; a
compliant mount structure having at least one convolution provided
on the outer wall, and the convolution defining an attachment
region within the at least one convolution; and a connector
attached to the attachment region.
2. The compliant mount assembly of claim 1 wherein the compliant
mount structure is formed in the outer wall of the conduit.
3. The compliant mount assembly of claim 2 wherein the compliant
mount structure is integral with the outer wall.
4. The compliant mount assembly of claim 1 wherein the at least one
convolution does not circumscribe the conduit.
5. The compliant mount assembly of claim 1 wherein the at least one
convolution includes two convolutions.
6. The compliant mount assembly of claim 5 wherein the two
convolutions are oval-shaped.
7. The compliant mount assembly of claim 6 wherein the two
convolutions are non-uniform.
8. The compliant mount assembly of claim 6 wherein the attachment
region is circular.
9. The compliant mount assembly of claim 1 wherein the at least one
convolution includes a set of three discrete convolutions.
10. The compliant mount assembly of claim 9 wherein the three
discrete convolutions are chevron-shaped.
11. The compliant mount assembly of claim 1 further comprising at
least one stiffening bar provided along the at least one
convolution.
12. The compliant mount assembly of claim 11 wherein the at least
one stiffening bar comprises two stiffening bars defining a
stiffening axis.
13. The compliant mount assembly of claim 1 wherein the conduit
includes a flat portion provided on the outer wall and the
compliant mount structure is provided on the flat portion.
14. A compliant mount structure for mounting a connector to an
outer wall of a conduit, the compliant mount structure comprising:
at least one convolution integrally formed in the outer wall to
form a monolithic structure with the outer wall and the at least
one convolution defining an attachment region within the at least
one convolution; wherein the connector attaches at the attachment
region.
15. The compliant mount structure of claim 14 wherein the at least
one convolution does not circumscribe the conduit.
16. The compliant mount structure of claim 14 wherein the at least
one convolution is non-uniform.
17. The compliant mount structure of claim 14 wherein the at least
one convolution is formed as a set of discrete convolutions.
18. The compliant mount structure of claim 14 further comprising at
least one stiffening bar provided along the at least one
convolution.
19. A method of providing compliance between a connector and a
conduit, the method comprising: flexing at least one convolution
formed integrally and unitarily with an outer wall of the conduit
between opposing ends of the conduit in response to a force applied
to the connector coupled to the outer wall.
20. The method of claim 19 wherein flexing further comprises
flexing about two convolutions.
21. The method of claim 19 further comprising providing a
directionality for flexion of the convolution with at least one
stiffening bar provided along the at least one convolution.
22. The method of claim 19 wherein the convolution is formed
in-situ during electroforming of the conduit.
23. The method of claim 19 wherein the convolution reduces low
cycle fatigue reaction loads at the conduit and the connector.
24. A method of forming a compliant mount structure integral with
an outer wall of a conduit, the method comprising: unitarily
electroforming the conduit having the outer wall with at least one
integral convolution forming the compliant mount structure, with
the at least one convolution defining an attachment region within
the at least one convolution.
25. The method of claim 24 further comprising electroforming at
least one stiffening bar within along at least one convolution.
26. The method of claim 24 further comprising coupling a connector
to the conduit at the attachment region.
27. The method of claim 24 wherein electroforming includes
electroforming the at least one convolution forming the compliant
mount structure between opposing ends of the conduit.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 62/577,400, filed Oct. 26, 2017, which is
incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] Turbine engines, and particularly gas or combustion turbine
engines, are rotary engines that extract energy from a flow of
combusted gases passing through the engine in a series of
compressor stages, which include pairs of rotating blades and
stationary vanes, through a combustor, and then onto a multitude of
turbine stages, also including multiple pairs of rotating blades
and stationary vanes.
[0003] Structural attachment features such as duct assemblies or
mount structures are provided about the turbine engine and can
provide support for conduits for the flow of various operating
fluids to and from the turbine engine. In the compressor stages,
bleed air is produced and taken from the compressor via fluid
conduits. Bleed air from the compressor in the gas turbine engine
can be utilized in various ways. For example, bleed air can provide
pressure for the aircraft cabin, keep critical parts of the
aircraft ice-free, or can be used to start remaining engines.
[0004] Fluid conduits used to carry bleed air from the compressor
require rigidity under dynamic loading, flexibility under thermal
loading, and that capability to operate under high and low cycle
fatigue. These criteria are often antithetical and lead to
compromise solutions.
BRIEF DESCRIPTION OF THE INVENTION
[0005] In an aspect, the disclosure relates to a compliant mount
assembly including a conduit having an outer wall defining an
interior and extending between opposing ends. A compliant mount
structure has at least one convolution provided on the outer wall,
and the convolution defining an attachment region within the at
least one convolution. A connector attached to the attachment
region.
[0006] In another aspect, the disclosure relates to a compliant
mount structure for mounting a connector to an outer wall of a
conduit and includes at least one convolution integrally formed in
the outer wall to form a monolithic structure with the outer wall
and the at least one convolution defining an attachment region
within the at least on convolution. The connector attaches at the
attachment region.
[0007] In yet another aspect, the disclosure relates to a method of
providing compliance between a connector and a conduit including
flexing at least one convolution formed integrally and unitarily
with an outer wall of the conduit between opposing ends of the
conduit in response to a force appliance to a connector coupled to
the outer wall.
[0008] In yet another aspect, the disclosure relates to a method of
forming a compliant mount structure integral with an outer wall of
a conduit including electroforming the conduit having the outer
wall with the at least one convolution forming the compliant mount
structure defining an attachment region within the at least one
convolution.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] In the drawings:
[0010] FIG. 1 is a schematic, partially cut away view of a turbine
engine assembly with a fluid conduit mounted to an engine casing by
a connector.
[0011] FIG. 2 is a view of the fluid conduit of FIG. 1 with the
connector extending from a compliant mount structure.
[0012] FIG. 3 is cross-sectional view of the compliant mount
structure of FIG. 3 taken across section
[0013] FIG. 4 is another cross-sectional view of the compliant
mount structure of FIG. 2 taken across section IV-IV, showing the
stiffening bars.
[0014] FIG. 5 is a front view of the compliant mount structure of
FIG. 2 having the connector removed and illustrating directional
axes defined by stiffening bars.
[0015] FIG. 6 is a front view of an alternative compliant mount
structure.
[0016] FIG. 7 is a cross-sectional view of the compliance mount
structure of FIG. 6 taken across section VII-VII.
DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0017] Aspects disclosed herein relate to a compliant tunable
attachment structure for tuning local compliance and stiffness for
connector attachment regions. The compliant tunable attachment
structure can be formed as an electroformed component, having thin
walls in the range of 0.030 inches to 0.050 inches (about 0.75 to
1.25 millimeters). Connectors, typically having a nominal thickness
of 0.063 inches (1.60 mm), can be significantly stiffer than the
attachment location of the electroformed component, which can lead
to high frequency dynamic and low-cycle-fatigue thermal loading
inducing high local fatigue stresses at the electroformed walls.
The compliant tunable attachment structures provide for improved
compliance under local stresses and loading at connector
attachments to the thin electroformed walls. While the above
description described particular thicknesses for electroformed
walls and connectors, it should be understood that such elements
are not limited to the aforementioned thicknesses, and any suitable
thickness in a particular implementation is contemplated.
[0018] The compliant tunable attachment structures are described
herein in the environment of a turbine engine; particularly,
mounting a fluid conduit to an engine casing. It will be
understood, however, that aspects of the disclosure described
herein are not so limited and may have general applicability within
any engine mounting elements to one another, as well as in
non-aircraft applications, such as other mobile applications and
non-mobile industrial, commercial, and residential applications.
Furthermore, the compliant tunable attachment structure can have
applications in non-engine environments, where mounting attachment
features may benefit from improved loading compliance under
stressed operation, variable operational temperatures, or high or
low cycle fatigues, for example.
[0019] As used herein, the term "forward" or "upstream" refers to
moving in a direction toward the engine inlet, or a component being
relatively closer to the engine inlet as compared to another
component. The term "aft" or "downstream" used in conjunction with
"forward" or "upstream" refers to a direction toward the rear or
outlet of the engine or being relatively closer to the engine
outlet as compared to another component. Additionally, as used
herein, the terms "radial" or "radially" refer to a dimension
extending between a center longitudinal axis of the engine and an
outer engine circumference. Furthermore, as used herein, the term
"set" or a "set" of elements can be any number of elements,
including only one.
[0020] As used herein, the term "compliance" or "compliant" means
the tendency towards being adaptable or flexible to a stress force
acting on the element. A "compliant mount structure" as described
herein permits movement or flexion in at least one degree of
freedom, linear or rotational. For example, the compliant mount
structure as described herein can be flexible to comply with a
stress force action on elements at the compliant mount
structure.
[0021] As used herein, the term "tunable" or "tuned" means that the
structure of an element can be adapted or modified to suit
particular conditions. For example, the compliant mount structure
as described herein can be tuned to flex under an anticipated range
of stress forces without breaking or fracturing.
[0022] All directional references (e.g., radial, axial, proximal,
distal, upper, lower, upward, downward, left, right, lateral,
front, back, top, bottom, above, below, vertical, horizontal,
clockwise, counterclockwise, upstream, downstream, forward, aft,
etc.) are only used for identification purposes to aid the reader's
understanding of the present disclosure, and do not create
limitations, particularly as to the position, orientation, or use
of aspects of the disclosure described herein. Connection
references (e.g., attached, coupled, connected, and joined) are to
be construed broadly and can include intermediate members between a
collection of elements and relative movement between elements
unless otherwise indicated. As such, connection references do not
necessarily infer that two elements are directly connected and in
fixed relation to one another. The exemplary drawings are for
purposes of illustration only and the dimensions, positions, order
and relative sizes reflected in the drawings attached hereto can
vary.
[0023] Referring to FIG. 1, a turbine engine assembly 10 defines a
longitudinal engine centerline 12 extending from forward to aft. A
turbine engine 16, a fan assembly 18, and a nacelle 20 can be
included in the turbine engine assembly 10, with portion of the
nacelle 20 cut away for clarity. The turbine engine 16 can include
an engine core 22 having a compressor section 24, a combustion
section 26, a turbine section 28, and an exhaust section 30. An
inner cowl 32 radially surrounds the engine core 22. The nacelle 20
surrounds the turbine engine 16 including the inner cowl 32 and the
core engine 22. In this manner, the nacelle 20 forms an outer cowl
34 radially surrounding the inner cowl 32. The outer cowl 34 is
spaced from the inner cowl 32 to form an annular passage 36 between
the inner cowl 32 and the outer cowl 34. The annular passage 36
characterizes, forms, or otherwise defines a nozzle and a generally
forward-to-aft bypass airflow path. A fan casing assembly 37 having
an annular forward casing 38 and an aft casing 39 can form a
portion of the outer cowl 34 formed by the nacelle 20 or can be
suspended from portions of the nacelle 20 via struts (not shown) or
other suitable mounting structures.
[0024] In operation, air flows through the fan assembly 18 and a
first portion 40 of the airflow is channeled through compressor
section 24 wherein the airflow is further compressed and delivered
to the combustion section 26. Hot products of combustion from the
combustion section 26 are utilized to drive turbine section 28 and
thus produce engine thrust. The annular passage 36 is utilized to
bypass a second portion 42 of the airflow discharged from fan
assembly 18 around engine core 22.
[0025] A fluid conduit 50 can extend from the compressor section 24
of the engine core 22 to the turbine section 28 of the engine core
22, passing exterior of the engine core 22 through the annular
passage 36. In one non-limiting example, the fluid conduit 50 can
be a bypass air conduit or bleed air conduit providing unheated air
to the turbine section 28, bypassing the combustion section 26. A
connector 52 can mount the fluid conduit 50 to the outer cowl 34 at
a compliant mount structure 54. In one example, the connector 52
can be a mount bracket.
[0026] It should be appreciated that while the fluid conduit 50 is
shown as exterior of the engine core 22 and mounted to the outer
cowl 34 by the connector 52, it is further contemplated that the
connector 52 and the fluid conduit 50 can be positioned interior of
the engine core 22, with the connector 52 mounted to the inner cowl
32, while positioned exterior of the airflow path through the
engine core 22. Furthermore, any suitable mounting position for the
fluid conduit 50 and connector 52 is contemplated, as may be
desirable in other engines or other suitable environments. Further
still, the fluid conduit 50 need not be a fluid conduit, but can be
a structural member, utilized for providing improved stiffness or
for mounting other engine components within the turbine engine
assembly 10.
[0027] The turbine engine assembly 10 can pose unique stress
management challenges, such as directional loading, thermal
loading, or other stress magnitudes during engine operation. The
compliant mount structure 54 can be utilized to mitigate such
challenges.
[0028] Referring now to FIG. 2, the compliant mount structure 54 is
provided on the fluid conduit 50 and can be formed as a portion of
the fluid conduit 50. The compliant mount structure 54 can be
formed integrally with the fluid conduit 50, for example, forming a
unitary structure or a monolithic structure, as opposed to the
combination of two distinct elements. Such a formation can be
accomplished through additive manufacturing, such as 3D printing or
electroforming, for example. The fluid conduit can have an outer
wall 51 extending between opposing ends 55 and defining an interior
53. In one example, the compliant mount structure 54 can be formed
on a flat, planar portion of the fluid conduit 50, while it is
contemplated that the compliant mount structure 54 can be formed on
a curved or arcuate surface, or any other surface of the fluid
conduit 50 suitable for mounting the connector 52, such as at a
bend or elbow of the fluid conduit 50.
[0029] A set of convolutions 56 can at least partially form the
compliant mount structure 54 having an inner convolution 58 and an
outer convolution 60. The convolutions 56 have substantially oval
shapes, while any shape is contemplated, such as circular,
triangular, curved, linear, rectilinear, or any combination thereof
in non-limiting examples. The connector 52 can mount to the fluid
conduit 50 interior of the set of convolutions 56. It should be
appreciated that while only two convolutions 56 are shown, any
number of convolutions, including one or more convolutions is
contemplated. A set of stiffening bars 62 can be provided on the
convolutions 56.
[0030] Referring now to FIG. 3, a cross section taken across
section of FIG. 2 better illustrates the geometry of the
convolutions 56 having a concave side 70 and a convex side 72 on
opposing sides of the compliant mount structure 54, defining a
channel 74 within the fluid conduit 50 at the concave side 70. The
convolutions 56 can be nested, non-uniform diaphragm convolutions,
for example, with the outer convolution 60 radially exterior of the
inner convolution 58 relative to the connector 52. The shaped
concave and convex sides 70, 72 of the convolutions 58, 60 provide
a geometry capable of improved compliance for the compliant mount
structure 54. The particular geometry of the convolutions 58, 60,
such as the orientation of the concave side 70, can be tailored to
move or flex in a particular way or having a particular
directionality. For example, the compliant mount structure 54 can
tend to flex inwardly at the concave side 70, while flexing
outwardly at the convex side 72. Furthermore, the orientation of
the concave and convex sides 70, 72 can be used to tailor
anticipated flexional directionality for the compliant mount
structure 54. Such an anticipated flexional directionality can be
determined using finite element analysis, for example. Therefore,
different exemplary organizations, for example, can have the
concave sides 70 on the bottom or the convex side 72 on the top, or
any combination thereof, or varying combinations within the same
convolution 56 that change along the convolution 56. While shown as
having a substantially uniform wall thickness for the convolutions
56 or compliant mount structure with that of the conduit 50, it is
contemplated that the convolutions 56 or compliant mount structure
can be formed as portions of the conduit 50 having varying
thicknesses, permitting compliance at the convolutions 56 or
compliant mount structure relative to the conduit 50.
[0031] The convolutions 56 can be tailored to move in two degrees
of freedom, to permit flexion of the connector 52 in any desired
directionality relative to the fluid conduit 50. The connector 52
is jointed to the local wall section via in-situ electrodeposition,
blazing, welding, or other metal joining method in non-limiting
examples. Specifically, a set of nested convolutions with a common
geometric center can have at most two rotational degrees of
freedom. Based on the relative directional stiffness of a set of
convolutions, each set of convolutions can share a portion of the
rotation for each degree of freedom. However, a universal system
having six degrees of freedom is possible if the geometric centers
of the convolution sets are both displaced from each other and
there are at least three sets. The range of the universal system is
then limited by the magnitude of the offsets between the sets of
convolutions.
[0032] Furthermore, the particular geometry of the nested,
non-uniform convolutions can be tailored to a specific required
stiffness, compliance, or maximum peak stress. Different
thicknesses, organizations, orientations, or geometries for the
convolutions 56 can be utilized to achieve such particular
stiffnesses, compliances, or stresses. For example, the
cross-sectional profiles for the convolutions 56 or portions
thereof can be pointed, chevron, triangular, arcuate, linear,
segmented, squared, or rectilinear, or any combination thereof in
non-limiting examples. Furthermore, different numbers of
convolutions 56, having different or variable thicknesses or
cross-sectional areas can be utilized to tailor or tune the
compliant mount structure 54 to the particular local stiffnesses,
compliances, or anticipated stresses or loading.
[0033] Further yet, the convolutions 56 can be uniform or
non-uniform. A non-uniform convolution can have a variable shape,
cross-sectional area, or cross-sectional distance in non-limiting
examples. Additionally, non-uniformities can include non-uniform
structures, shapes, thicknesses, cross-sectional areas or
cross-sectional distances in further non-limiting examples.
Alternatively, a uniform convolution, for example, can have a
constant cross-sectional area or thickness, around the entirety of
the convolution radially outward from the connector 52, for
example, such as a symmetric circular convolution.
[0034] Further still, the convolutions can include any shape, and
are not limited to the oval geometry. Exemplary additional shapes
can include convolutions or sets of convolutions that are circular,
oval, rounded, arcuate, chevron, coiled, twisted, spiral, helical,
whorl, volute, linear, rectilinear, triangular, square, sinusoidal,
geometric, or unique, or any combination thereof in non-limiting
examples. Similarly, the convolutions 56 need not be wholly
concentric about the connector 52. Rather, the convolutions 56 can
extend partially about the connector 52, having multiple discrete
portions forming the convolutions (see FIG. 5, for example).
Similarly, different layers of convolutions or discrete portions
thereof can have different shapes. Furthermore, the connector 52
can be offset from a center of the convolutions 56, or can be
positioned nearer to convolutions 56 having a specific
predetermined direction or magnitude of compliance or flexion.
[0035] Such tuning or tailoring of the geometry, orientation, and
organization for the compliant mount structure 54 and the
convolutions 56 can provide for particularly tuning the local
required stiffness or maximum peak stress based upon anticipated
stresses or loading, or particular directionalities thereof.
Therefore, the compliant mount structure 54 can be specifically
formed to a particular local stiffness, compliance, or
directionality for the compliant mount structure. Additionally, the
compliant mount structure 54 can include a tunable dynamic response
of the combined effects of the supported mass, such as the
connector 52, and the directional stiffness of the compliant mount
structure 54. Such particular tuning as described herein can be
modeled with finite element simulations or analysis, in
non-limiting examples, in order to comply with anticipated stresses
or loading at the compliant mount structure 54.
[0036] Referring now to FIG. 4, a cross-section of the compliant
mount structure 54 taken across section IV-IV of FIG. 2 better
illustrates the stiffening bars 62 as an insert-molded in-situ set
of stiffening bars 62 provided within the convolutions 56. The
stiffening bars 62 can be a portion of material that is directly
jointed in-situ, via electrodeposition, with the rest of the
convolution 56. In one example, the stiffening bars 62 can be a
continuous wall section of the shape or geometry of the fluid
conduit 50 through the convolution 56. The stiffening bars 62 can
include a first thickness 76, and the fluid conduit 50 can include
a second thickness 78. The first thickness 76 of the stiffening
bars 62 can be greater than the second thickness 78 of the fluid
conduit 50. Alternatively, it is contemplated that the first
thickness 76 of the stiffening bars 62 can be less than the second
thickness 78 of the fluid conduit 50, or having equal thicknesses
76, 78. Such variable thicknesses can provide for tailored
stiffnesses at and along the stiffening bars 62, which can provide
for local stiffnesses or directionality of flexion for the
convolutions 56.
[0037] Referring now to FIG. 5, the compliant mount structure 54 is
shown on a flat portion 90, which can be formed on the outer wall
51 of the fluid conduit 50. The connector 52 has been removed for
clarity, exposing a connector attachment region 80 provided
interior of the set convolutions 56. The shape of the connector
attachment region 80 can be defined by the set of convolutions 56,
or the set of convolutions 56 can be shaped and arranged based upon
or to define a shape for the connector attachment region 80, or
tailored to a particular connector 52. It is further contemplated
that a portion of the connector attachment region 80 includes an
optional opening 92 (shown in broken line), defining an aperture
within the connector attachment region 80 for fluidly coupling the
connector 52 to the fluid conduit 50 at the compliant mount
structure 54, where such fluid communication may be desirable.
[0038] A first set of two stiffening bars 82 are provided on
opposite sides of the outer convolution 60, and a second set of two
stiffening bars 84 provided on opposite sides of the inner
convolution 58, offset from the first set of stiffening bars 82.
While provided on opposite sides of the convolutions 56, it should
be appreciated that the stiffening bars 82, 84 can be positioned
anywhere along the convolutions 56, or along the fluid conduit 50
between the convolutions 56. Furthermore, while only two stiffening
bars 82, 84 are shown with each convolution 58, 60, any number of
stiffening bars 82, 84, including one or more, can be utilized in
any organization or location, or having any geometry. In one
non-limiting, alternative example, the stiffening bars 82, 84 can
be non-uniform portions of the convolutions 56, such as having an
irregular shape, structure, or thickness relative to the
convolution 56 or the fluid conduit 50, for example.
[0039] A first stiffened axis 86 can be defined extending linearly
between the first stiffening bars 82. The first set of stiffening
bars 82 can tune a directional compliance about the first stiffened
axis 86 in order to meet particular stiffness or compliance
requirements at maximum peak stresses in a particular direction or
magnitude along or in the direction of the stiffened axis 86.
Specifically, the stiffened axis 86 can limit or prevent rotation
about a degree of freedom defined along the stiffened axis 86.
[0040] Similarly, a second stiffened axis 88 can be defined
extending linearly between the second stiffening bars 84, which can
be used to tune a second directional stiffness about the second
stiffened axis 88, in addition to the first stiffened axis 86.
Utilizing multiple stiffening bars 62 or multiple set of stiffening
bars 62 can be used to particularly tailor directional stiffness or
rotational compliance for the compliant mount structure 54.
[0041] Referring now to FIG. 6, an alternative compliant mount
structure 100 can include a first set of chevron convolutions 102
and a second set of chevron convolutions 104, each having chevron
shapes, while any number of sets of convolutions is contemplated.
The first set of chevron convolutions 102 is positioned exterior of
the second set of convolutions 104, relative to a mounting bracket
attachment region 106. Each set of chevron convolutions 102, 104
includes three discrete chevron convolutions, while any number is
contemplated within each individual set. The sets of chevron
convolutions 102, 104 define a hexagonal shape for the mounting
bracket attachment region 106, which can be tailored to a hexagonal
connector, for example.
[0042] The organization of the two sets of three chevron
convolutions 102, 104 defines three of flexure axes 108, providing
three axes about which the compliant mount structure 100 can flex,
as well as local tailored directionalities based upon the geometry
of each individual chevron convolution 102, 104.
[0043] Referring now to FIG. 7, a cross-sectional view taken across
section VII-VII of FIG. 6 better illustrates the geometry of the
chevron convolutions 102, 104. Each chevron convolution 102, 104 is
rectilinear, having a triangular profile defining a channel 110 and
a point 112. The first set of chevron convolutions 102 can have a
greater depth 114 than a lesser depth 116 of the second set of
convolutions 104. The lesser depth 116 can provide for decreased
flexion adjacent the mounting bracket attachment region 106, which
can provide for increased stiffness adjacent to a connector
attached to the compliant mount structure 100.
[0044] It should be understood that there is a myriad of different
combination for the shape and structure of the compliant mount
structure, and that the examples shown in FIGS. 2-7 are only
exemplary of two such examples. For example, there can be any
number of convolutions provided in the compliant mount structure.
Each convolution can be separated into any number of discrete
convolution segments, in order to provide discrete stiffness or
directionality within the convolutions, without requiring the
particular stiffening bars provided in the convolutions, or in
addition to the stiffening bars. Furthermore, the convolutions can
extend in any direction, interior or exterior of the fluid
conduits, in order to provide further directionality for flexion of
the compliant mount structure.
[0045] In one example, a method of providing compliance between a
connector 52 and a conduit 50 can include flexing at least one
convolution 56 formed integrally and unitarily with an outer wall
51 of the conduit 50 between opposing ends 55 of the conduit 50 in
response to a force applied to a connector 52 coupled to the outer
wall 51. The method can optionally include wherein flexing further
comprises flexing about two convolutions 58, 60. The method can
optionally include wherein the at least two convolutions 58, 60 are
non-uniform. The method can optionally further include providing a
directionality for flexion of the compliant mount structure 54 with
at least one stiffening bar 62 providing along the at least one
convolution 56. The method can optionally include wherein the at
least one stiffening bar 62 includes two stiffening bars 62
defining a stiffening axis 86, 88 defining the directionality for
flexion of the compliant mount structure 54. The method can
optionally include wherein the compliant mount structure 54 is
formed in-situ during electroforming of the conduit 50. The method
can optionally include wherein the compliant mount structure 54
reduces low cycle fatigue reaction loads at the conduit 50 and the
connector 52. The method can optionally include wherein the at
least one convolution is electroformed in-situ with the conduit 50,
and in integral or unitary with the conduit to form a monolithic
structure.
[0046] In another example, a method of forming a compliant mount
structure 54 integral with an outer wall 51 of a conduit can
include unitarily electroforming the conduit 50 having the outer
wall 51 with at least one integral convolution 56 forming the
compliant mount structure 54, with the at least one convolution 56
defining an attachment region 80 within the at least one
convolution 56. The method can optionally include electroforming at
least one stiffening bar 62 along the at least one convolution 56.
The method can optionally include wherein the at least one
stiffening bar 62 includes providing a directionality for flexion
of the compliant mount structure 54. The method can optionally
include coupling a connector 52 to the conduit 50 at the attachment
region 80. The method can optionally include wherein electroforming
includes electroforming the at least one convolution 56 forming the
compliant mount structure 54 between opposing ends 55 of the
conduit 50. The method can optionally include wherein the at least
one convolution is electroformed in-situ with the conduit 50, and
in integral or unitary with the conduit to form a monolithic
structure.
[0047] The compliant mount structures can be formed integrally with
the fluid conduits, and can be formed by additive manufacturing
such as electroforming. Electroforming the fluid conduits with the
compliant mount structures provides for in-situ geometries capable
of reducing or complying with local stresses during formation of
the conduit. In one example, the fluid conduit having a particular
geometry for the compliant mount structure can be formed in a
sacrificial mandrel, and the fluid conduit and compliant mount
structure can be electroformed about the mandrel. Utilizing a
common mandrel electroform manufacturing process requires no
additional cost or post processing for forming the compliant mount
structures. Electroformed components can have thin walls in the
range of 0.030 inches to 0.050 inches (about 0.75 to 1.25
millimeters), for example, while greater or lesser thicknesses are
contemplated. The compliant mount structures can provide for
minimizing and distributing local stresses, such as operating under
high frequency dynamic and low-cycle-fatigue thermal loading, which
can introduce high local fatigue stresses in the thin electroformed
walls.
[0048] The tunable compliant mount structures provide for a tunable
compliance for the attachment of connectors or other similar
attachment members. Typical fluid delivery components are made of a
uniform thickness of formed sheet metal or cylindrical tubing, and
are tailored to worst-case local stresses with an over-design
thickness, resulting in increased thickness with non-compliant
rigidity. The tunable compliant mount structures can improve the
compliance under local stresses and loading, while permitting a
reduced overall thickness and weight, achievable with
electroforming manufacturing. Specifically, the tunable compliant
mount structure and provide for improving directional compliance
and stiffness to reduce low-cycle fatigue stress and dynamic
response (high-cycle fatigue). Furthermore, the compliance can be
further tailored by adding directionality to the loading based upon
the geometry of the particular compliant mount structure.
Therefore, the compliant mount structure can minimize peak stress
magnitudes, while also minimizing overall weight and assembly
complexity. Minimized weight can minimize engine specific fuel
consumption.
[0049] To the extent not already described, the different features
and structures of the various embodiments can be used in
combination, or in substitution with each other as desired. That
one feature is not illustrated in all of the embodiments is not
meant to be construed that it cannot be so illustrated, but is done
for brevity of description. Thus, the various features of the
different embodiments can be mixed and matched as desired to form
new embodiments, whether or not the new embodiments are expressly
described. All combinations or permutations of features described
herein are covered by this disclosure.
[0050] This written description uses examples to describe aspects
of the disclosure described herein, including the best mode, and
also to enable any person skilled in the art to practice aspects of
the disclosure, including making and using any devices or systems
and performing any incorporated methods. The patentable scope of
aspects of the disclosure is defined by the claims, and may include
other examples that occur to those skilled in the art. Such other
examples are intended to be within the scope of the claims if they
have structural elements that do not differ from the literal
language of the claims, or if they include equivalent structural
elements with insubstantial differences from the literal languages
of the claims.
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